Introduction to Process Safety Management (PSM)
An introduction to Process Safety Management for highly hazardous chemicals. The course explains why PSM exists, where it applies, and each of the 14 elements – from process safety information and PHA to MOC, mechanical integrity, incident investigation and audits.
At a glance
- 3 days
Who it's for
- HSE officers; process & chemical engineers
- Operations, production, maintenance & reliability staff
- Plant managers & supervisors; QA; compliance & risk managers
- Contractors in process facilities
Learning objectives
- Summarise OSHA 29 CFR 1910.119 and CAAA
- Section 304 requirements
- Describe the 14 PSM elements
- Explain PHA steps and methods
- Describe MOC, PSSR, mechanical integrity, hot work, incident investigation and emergency response
Detailed content
- Major accidents record; OSHA response; Clean Air
- Act Amendments; benefits
- What is a 'process'; targeted industries; exemptions; reducing risk
- Chemical hazards; process technology; BFD, PFD, P&ID; equipment
- PHA steps, prioritisation, methods (What-if, checklist, HAZOP, FMEA, FTA)
- PHA team; findings; revalidation
- Requirements, elements, annual review
- Employee involvement; initial & refresher training; documentation
- Review
- Employer & contractor responsibilities; PSSR
- MI program, inspection & testing, deficiencies; hot- work permits
- Response, Audits, Trade Secrets
- Management of change; incident investigation; emergency planning; compliance audits
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- Module 1 – Why PSM
- Module 2 – Applicability
- Module 3 – Process Safety Information
- Module 4 – Process Hazard Analysis
- Module 5 – Operating Procedures
- Module 6 – Employee Participation & Training
- Module 7 – Contractors & Pre-Startup Safety
- Module 8 – Mechanical Integrity & Hot Work
- Module 9 – MOC, Investigation, Emergency
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Solve a real problem with 8D or A3 from containment to verification
- Fishbone and 5-Why workshop with evidence checks
- Site inspection and hazard spotting with photos
- Risk assessment and control hierarchy for a real task
Tools and templates you keep
- 8D report and A3 templates
- Root-cause verification checklist
- Risk-assessment (HIRA) form
- Inspection checklists and toolbox-talk template
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- Ford 8D / VDA problem-solving guidance
- ASQ Quality Improvement tools
- ISO 45001:2018
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Health, Safety & Environment · Expert
Frequently asked questions
How long is Introduction to Process Safety Management (PSM)?
The program runs 3 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.